Detachable cleat system

ABSTRACT

The present invention relates to a sole made from a first material, at least one receptacle made from a second material, and at least one stud, which can be releasably mounted within the receptacle by inserting a fastening projection of the stud into the receptacle. The fastening projection includes a first locking member, and the receptacle includes a flexible wall having a second locking member. The flexible wall is deflected when the fastening projection is inserted into the receptacle until the first and the second locking members engage.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.11/403,122, filed on Apr. 12, 2006 now U.S. Pat. No. 7,353,627, which isa continuation of U.S. patent application Ser. No. 10/688,793, filed onOct. 17, 2003 now U.S. Pat. No. 7,047,675, which is acontinuation-in-part of U.S. patent application Ser. No. 10/125,057,filed on Apr. 18, 2002, now U.S. Pat. No. 6,748,677, which are allhereby incorporated herein by reference in their entireties. Thisapplication incorporates by reference, and claims priority to and thebenefit of, German patent application serial number 10248482.1, filed onOct. 17, 2002, and German patent application serial number 10118986.9,which was filed on Apr. 18, 2001.

TECHNICAL FIELD

The present invention relates to an article of footwear, the outsole ofwhich is provided with exchangeable studs. In particular, the presentinvention relates to a sole with at least one receptacle and at leastone stud that can be releasably mounted in the receptacle.

BACKGROUND

It is known to provide sports shoes or walking boots, and in particularsoccer shoes, with studs in order to increase the grip of the shoe, inparticular, on soft ground such as grass. The term “studs” is to beunderstood in the context of the present invention as meaning allpossible elements which are arranged on outsoles of footwear in order toincrease grip. The term “studs” is intended to include, for example,studs for soccer shoes, spikes for golf shoes, and studs for walkingboots.

If the shoes are to be used on different ground conditions, it isadvantageous if the studs are releasably attached to the sole to allowthe shoes to be adapted to the different ground conditions. It has beenknown to attach studs to the soles of soccer shoes by means of threads.In addition to being able to adapt the shoe to a particular groundcondition, worn studs can be replaced so that a new shoe is notnecessary. If, however, during a soccer game (or a golf tournament) thestuds must be replaced in a very short time due to changing weatherconditions and/or changing ground conditions, screw studs anchored byscrew threads or by additional pins or expanding elements, etc., aredisadvantageous due to the time required to change the studs.

Other attachment systems exist where, for example, the stud can be“clipped” into a corresponding receptacle of the sole simply byinserting the stud without having to perform any additional assemblystep. Such constructions are, for example, disclosed in U.S. Pat. No.5,638,615 and U.S. Pat. No. 4,035,934, the disclosures of which arehereby incorporated herein by reference in their entireties.

U.S. Pat. No. 5,638,615 discloses a metal socket with a circular snapring provided therein. The snap ring is made from flexible steel and,together with the socket, is embedded in a receptacle for the studduring the manufacture of the sole. When a base portion of the stud tobe mounted is inserted, the snap ring is expanded before it snaps intoan annular groove of the base portion and thereby fastens the stud. Therotationally symmetric form of the receptacle and the stud allows forrotation of the mounted stud in the receptacle.

Similarly, U.S. Pat. No. 4,035,934 discloses two metal spring pinsarranged in a receptacle, which are deflected during insertion of a basemember of the stud and engage a corresponding groove of the base memberwhen the base member is completely inserted. The complete receptaclewith the spring pin and other components is preassembled on a plateduring the manufacture of the sole and is subsequently attached in acorresponding bore of the sole.

Disadvantages of the studs of U.S. Pat. Nos. 5,638,615 and 4,035,934include the manufacturing complexity and the resulting costs. Aspreviously mentioned, an initial preassembly of the receptacle assemblyis required and the receptacle assembly is subsequently connected to thesole in a further manufacturing step. Also, the large number of smallparts used renders automation difficult, such that a substantial amountof manual work is required. Further, there are metal parts used in thereceptacle assembly that are susceptible to rust, and there is alwaysthe danger of losing a spring or a snap ring when the studs arereplaced.

U.S. Pat. No. 5,848,482, the disclosure of which is hereby incorporatedherein by reference in its entirety, discloses a stud, where thereceiving unit and/or the mounting pin of the stud are made from adeformable elastomeric material. During insertion of the receiving unitand/or the mounting pin, the material is compressed and expands only inthe mounting position of the stud, which is thereby fastened to thesole. This assembly allows for the stud to be detached from the sole.However, the force required to mount and release the stud isconsiderable due to the necessary compression of the material of thestud and/or receiving unit. Consequently, it is difficult to replacemultiple studs on a shoe in a short duration of time.

It is, therefore, an object of the invention to provide a sole for thereleasable attachment of at least one stud, which combines theadvantages of an easy mounting of the stud with a simple and costefficient manufacture of the sole and which does not require the use ofa large number of small parts.

SUMMARY OF THE INVENTION

The present invention relates to a sole with at least one receptacle andat least one stud, which can be releasably mounted in the receptacle byinsertion. A fastening projection extending from the stud and includinga locking member is insertable into the receptacle, thereby deflecting aflexible wall within the receptacle. The flexible wall also includes alocking member that engages the stud locking member to preventinadvertent release of the stud.

The flexible wall of the receptacle acts like a “spring element,”allowing interlocking of the locking members when the fasteningprojection of the stud is inserted. Because the flexible wall is anintegral part of the sole, no additional components are required, incontrast to the prior art. On the contrary, a sole in accordance withthe invention may be manufactured as a single piece, including thereceptacle with the flexible wall and the locking member. Typically, acavity is provided in the sole adjacent to the receptacle, so that theflexible wall is deflected into the cavity during insertion of thefastening projection. This facilitates elastic deflection of the wall,without having to provide special, highly elastic materials in thereceptacle.

The fastening projection of the stud can be oblong and the wall betweenthe cavity and the receptacle can be generally parallel to alongitudinal axis of the fastening projection. Thus, the stud is securedagainst rotation in the receptacle. This is desirable, especially if thestuds have a distinct asymmetric shape in order to meet specificfunctional requirements. Further, if desired, a key and slot or othermating structure can be provided on the projection and in the receptacleso that the stud can be inserted in solely a single orientation.

In one aspect, the invention relates to a sole including a bottomsurface defining a receptacle and a stud removably inserted therein. Thereceptacle includes a flexible wall and a first locking member disposedon an internal surface of the flexible wall. The stud includes aground-engaging portion and a fastening projection extending therefrom.The fastening projection includes a second locking member disposed on anexternal surface thereof and is for insertion into the receptacle. Thefastening projection deflects the flexible wall when inserted into thereceptacle until the first locking member and the second locking memberengage.

In another aspect, the invention relates to an article of footwearincluding an upper and a sole. The sole includes a bottom surfacedefining a receptacle and a stud removably inserted therein. Thereceptacle includes a flexible wall and a first locking member disposedon an internal surface of the flexible wall. The stud includes aground-engaging portion and a fastening projection extending therefrom.The fastening projection includes a second locking member disposed on anexternal surface thereof and is for insertion into the receptacle. Thefastening projection deflects the flexible wall when inserted into thereceptacle until the first locking member and the second locking memberengage.

In yet another aspect, the invention relates to a stud for a shoe sole.The stud includes a ground-engaging portion and a fastening projectionextending from the ground-engaging portion. The fastening projectionincludes a locking member disposed on an external surface thereof and isinsertable into a receptacle disposed in the shoe sole. The fasteningprojection deflects a flexible wall of the receptacle when inserted intothe receptacle until the locking member engages a mating locking memberdisposed within the receptacle.

In various embodiments of the foregoing aspects of the invention, thesole forms a cavity disposed adjacent the flexible wall of thereceptacle. The cavity can receive the flexible wall when deflected bythe fastening projection. The first locking member can be a protuberanceand the second locking member can be a mating recess for engaging theprotuberance when the fastening projection is inserted into thereceptacle. In another embodiment, the first locking member can be arecess and the second locking member can be a mating protuberance forengaging the recess when the fastening projection is inserted into thereceptacle. During insertion of the fastening projection, the flexiblewall is pressed into the cavity until the protuberance and thecorresponding recess are aligned and engage each other. In oneembodiment, the cavity can be formed as a recess, open to a top surfaceof the sole.

In other embodiments, the receptacle can include a second flexible walland an additional first locking member disposed on an internal surfaceof the second flexible wall. The fastening projection can include acorresponding additional second locking member disposed on the externalsurface of the fastening projection. The sole can further form a secondcavity disposed adjacent the second flexible wall of the receptacle. Thesecond cavity can receive the second flexible wall when deflected by thefastening projection.

Furthermore, the receptacle, the cavity, and the flexible wall can beintegrally formed with the sole. In one embodiment, the fasteningprojection of the stud has a generally oblong shape. The flexiblewall(s) of the receptacle can be substantially parallel to alongitudinal axis of the fastening projection. In one embodiment, atleast one side of the receptacle is at least partially circumscribed bythe cavity and the flexible wall. The first flexible wall and the secondflexible wall can be generally disposed on opposite sides of thereceptacle. The two second locking members can be disposed on a firstlongitudinal side and a second longitudinal side of the fasteningprojection, respectively, and the two first locking members can bedisposed on the corresponding flexible walls of the receptacle.

In addition, the ground-engaging portion of the stud can optionallyinclude an engagement feature for facilitating removing the stud fromthe receptacle. The engagement feature can include at least one recessdisposed on an external surface of the ground-engaging portion.Alternatively, the engagement feature can include two recesses generallydisposed on opposite sides of an external surface of the ground-engagingportion. In one embodiment, the receptacle is disposed at leastpartially within a downwardly projecting base member disposed on thebottom surface of the sole. The base member can optionally include aninsert disposed within a distal end of the receptacle. The insert canoptionally include a metal ring. The sole can include a plurality ofreceptacles and a plurality of corresponding studs.

In another aspect of the invention, a method for manufacturing a sole isprovided. Included in the method is the step of providing at least onereceptacle forming a cavity for receiving a stud including a fasteningprojection having at least a first locking means. The method alsoincludes the step of forming a sole body around the at least onereceptacle.

In one embodiment of the method, the receptacle includes at least oneintegral wall, where the wall includes at least a second locking means.The step of providing the at least one receptacle can also includeinjection molding the at least one receptacle. In another embodiment,the sole body is formed around the at least one receptacle in aninjection molding process. The at least one receptacle, in yet anotherembodiment, is formed within an insert. A plurality of receptacles canalso be provided. The method can further include the step of providing astud for insertion into the at least one receptacle. In anotherembodiment, the at least one receptacle is formed from a first materialhaving a first stiffness and the sole body is formed from a secondmaterial having a second stiffness.

In another aspect, the invention relates to a sole. The sole includes abottom surface defining a stud base. Also included is a receptacle, thereceptacle disposed at least partially within the stud base. Thereceptacle includes a flexible wall and a first locking member disposedon an internal surface of the flexible wall. The sole also includes astud where the stud includes a ground-engaging portion and a fasteningprojection extending from the ground-engaging portion for insertion intothe receptacle.

In one embodiment, the fastening projection of the stud further includesa second locking member disposed on an external surface and thefastening projection deflects the flexible wall when inserted into thereceptacle such that the first locking member and the second lockingmember engage. The sole can further include a cavity formed adjacent theflexible wall of the receptacle for receiving the flexible wall whendeflected by the fastening projection. In another embodiment, the firstlocking member includes a protuberance and the second locking memberincludes a mating recess for engaging the protuberance when thefastening projection is inserted into the receptacle. The receptacle canalso include a second flexible wall and an additional first lockingmember disposed on an internal surface of the second flexible wall. Inthis embodiment, the fastening projection also includes a correspondingadditional second locking member disposed on the external surface of thefastening projection. In yet another embodiment, the sole can furtherinclude a second cavity formed adjacent the second flexible wall of thereceptacle for receiving the second flexible wall when deflected by thefastening projection. The fastening projection of the stud, in anotherembodiment, has a generally oblong shape. In yet another embodiment, thetwo second locking members are disposed on a first longitudinal side anda second longitudinal side of the fastening projection and the two firstlocking members are disposed on corresponding flexible walls. The groundengaging portion of the stud can include an engagement feature forfacilitating removing the stud from the receptacle. In anotherembodiment, the sole is formed from a first material having a firststiffness and the receptacle is formed from a second material having asecond stiffness. The sole, in another embodiment, is injection moldedaround the receptacle.

These and other objects, along with advantages and features of thepresent invention herein disclosed, will become apparent throughreference to the following description, the accompanying drawings, andthe claims. Furthermore, it is to be understood that the features of thevarious embodiments described herein are not mutually exclusive and canexist in various combinations and permutations.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings are not necessarily to scale, emphasis instead generallybeing placed upon illustrating the principles of the invention. In thefollowing description, various embodiments of the present invention aredescribed with reference to the following drawings, in which:

FIG. 1 is a schematic perspective view of a front portion of a sole inaccordance with the invention;

FIG. 2 is a schematic top plan view of a portion of the sole of FIG. 1;

FIG. 3 is a schematic cross-sectional view of a detachable cleat systemin accordance with the invention taken along line 3-3 in FIG. 2;

FIG. 4 is a schematic exploded view of one embodiment of a detachablecleat system in accordance with the invention;

FIG. 5A is a schematic top view of the insert of FIG. 4

FIG. 5B is a schematic cross-sectional view of the insert of FIG. 4taken about line 5B-5B of FIG. 5A;

FIG. 5C is a schematic cross-sectional view of the insert of FIG. 4taken about line 5C-5C of FIG. 5A;

FIGS. 6A-6B are schematic top and side views of a ring for use in theinsert of FIG. 4;

FIG. 7 is a schematic cross-sectional view of another embodiment of adetachable cleat system in accordance with the invention;

FIG. 8 is a schematic plan view of a portion of a sole having analternative cavity shape and location in accordance with the invention;

FIG. 9 is a schematic exploded view of another embodiment of adetachable cleat system in accordance with the invention;

FIG. 10 is a schematic cross-sectional view of the detachable cleatsystem of FIG. 9; and

FIG. 11 is a schematic perspective view of one embodiment of a stud inaccordance with the invention.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the present invention are described below. It is,however, expressly noted that the present invention is not limited tothese embodiments, but rather the intention is that modifications thatare apparent to the person skilled in the art are also included. Inparticular, the present invention is not intended to be limited tosoccer shoes, but rather to be used for all types of footwear in whichstandard profiled soles are insufficient to ensure that the wearer doesnot slip, so projections that penetrate into the ground (studs, spikes,etc.) are used, and the projections are releasably connected to the shoesole. Further, only a left or right sole is depicted in any givenfigure; however, it is to be understood that the left and right solesare typically mirror images of each other and the description applies toboth left and right soles. In certain activities that require differentleft and right sole configurations or performance characteristics, thesoles need not be mirror images of each other.

FIG. 1 depicts a front portion of one embodiment of a sole 1 attached toan upper 49 in accordance with the invention. The sole 1 includes aplurality of integrally formed base members 10 projecting downwardlyfrom a bottom surface 3 of the sole 1 and to which a correspondingnumber of studs 20 are releasably attached. The arrangement of the basemembers 10 along the edge of the sole 1 is only one possibleconfiguration, as used in soccer shoes, for example; however, any numberor configuration of base members 10 and studs 20 is also contemplatedand within the scope of the invention. Alternatively or additionally,base members 10 can also be arranged in a heel portion (not shown) ofthe sole 1. In addition to the base members 10 for receiving thereleasable studs 20, one or more studs 2 can be provided integrally orrigidly anchored to the sole 1.

The stud 20, according to one embodiment, is depicted in FIG. 11. Thestud 20 includes a ground-engaging portion 25 and a fastening projection21 extending therefrom. The ground-engaging portion 25 has a generallyoblong, frusto-conical shape and the fastening projection 21 has agenerally oblong shape; however, the shape and size of theground-engaging portion 25 and the fastening projection 21 can be chosento suit a particular application. For example, the shape of thefastening projection 21 could be polygonal, arcuate, or combinationsthereof. In the present application, the term polygonal is used todenote any shape including at least two line segments, such asrectangles, trapezoids, triangles, etc. Arcuate shapes include, forexample, circular and elliptical.

Further, the fastening projection 21 includes a second locking member 23disposed on an external longitudinal surface 19 of the fasteningprojection 21. There can be an additional second locking member 23disposed on an opposite side of the fastening projection 21.Alternatively, the second locking member 23 can be disposed on an end ofthe fastening projection 21. The second locking member 23 is depicted asa generally rectangular recess; however, the second locking member 23could be essentially any size or shape to suit a particular application.In an alternative embodiment, the second locking member 23 could be aprotuberance.

The ground-engaging portion 25 includes an optional engagement feature22 for facilitating disengaging the stud 20 from the sole 1. Theengagement feature 22 shown is a recess disposed on an external surface29 of the ground-engaging portion 25 of the stud 20. Alternatively, theengagement feature 22 could include a second recess disposed on theopposite side of the stud 20 or could be disposed along an edge 33 ofthe ground-engaging portion 25.

Referring back to FIG. 1, two arrows 7 schematically indicate that thestud 20 is releasably mounted to the sole 1 by insertion of itsfastening projection 21 into a receptacle 11 at least partially formedand disposed within the corresponding base member 10. No other action,such as screwing or otherwise rotating the stud 20 is necessary for theattachment of the stud 20 after insertion of the fastening projection21.

To remove the stud 20 from the base member 10, the reverse movementtakes place, i.e., the stud 20 is pulled essentially vertically out ofthe receptacle 11. To assist in removing the studs 20, the engagementfeature 22 can be provided on the sides of the stud 20. The engagementfeature 22 can be engaged by a suitable claw-like tool to securely graspand remove the stud 20. Alternatively, the engagement feature 22 couldbe a slit-like recess disposed on the edge 33 of the stud 20 adjacentthe base member 10, such that a tool with a planar tip, such asscrewdriver, could be used to assist in removing the stud 20 by prying.In addition, other types of engagement features 22 can be provided forengagement with the tool, for example, circular recesses or any suitablelateral protrusion(s). The foregoing method of engaging and disengagingthe stud 20 allows a user to quickly replace all of the studs 20 on thesole 1 or any damaged studs, as necessary. Thus, the gripping propertiesof the shoe can be quickly adapted in response to changing groundconditions or stud wear, even during a game.

In the embodiment shown in FIG. 1, the fastening projection 21 of thestud 20, as well as the corresponding receptacle 11, have a generallyoblong shape and the cavities 15 generally extend parallel thereto.Thus, the stud 20, of which the fastening projection 21 also has anoblong shape, is secured against rotation. It is, however, also possibleto provide alternative or additional cavities 15 and corresponding walls16, which surround semicircularly the ends of the oblong receptacle 11(see FIG. 8).

Further, the receptacle 11 can have a distinct asymmetric shapecorresponding to a similar shape of the fastening projection 21, so thatthe stud 20 can only be inserted in a specific orientation. If the studs20 are different for different parts of the sole, it is further possibleto provide individually designed receptacles 11 and fasteningprojections 21, so that each stud 20 fits only into its correspondingreceptacle 11 or a limited number of receptacles 11. Alternatively, thereceptacles 11 could include one or more cavities 15 with correspondingwalls 16 having projections or recesses that are arranged around arotationally symmetric receptacle 11, so that rotation of the fasteningprojection 21 is possible inside the receptacle 11. In this case, thereceptacle 11 could include, for example, three cavities 15 withcorresponding walls 16. In addition, the external surfaces of theground-engaging portion 25 and the base member 10 can have correspondingshapes, such that the external surfaces are flush when the stud 20 isattached, so that the external surfaces smoothly conform to each other.

FIG. 2 shows a detailed view of a top surface 4 of a portion of the sole1 of FIG. 1. The sole 1 is manufactured from a first material and thereceptacles 11 arranged in the bottom of the sole 1 are manufacturedfrom a second material. The base member 10 can be either part of thereceptacle 11 or the sole 1. Mixed constructions are also contemplatedin accordance with the invention.

FIG. 3 is an enlarged cross-sectional view of the sole 1, the receptacle11, and the stud 20. As can be seen, two inwardly directed protuberances12 are arranged inside the receptacle 11, which engage the correspondingrecesses 23 of the fastening projection 21 of the stud 20 when it iscompletely inserted into the receptacle 11. The inwardly directedprotuberances 12 form the first locking members and are disposed oninternal surfaces 17 of the flexible walls 16 of the receptacle 11.Alternatively, the first locking members 12 could be recesses thatengage laterally extending protuberances (second locking members 23) onthe fastening projection 21 of the stud 20. Also shown are two cavities15 disposed adjacent the flexible walls 16 to permit flexure of thewalls 16 when the stud fastening projection 21 is inserted into thereceptacle 11.

With further reference to FIGS. 2-3, the two cavities 15 are arrangedinside the receptacle 11. The cavities 15 are generally oblong recessesin the receptacle 11 and are open to the top side. This arrangementfacilitates manufacture and removal from a mold, if the receptacle 11 ismade from a single piece of plastic material by injection molding.

When, as indicated in FIG. 3 by vertical arrow 39, the fasteningprojection 21 is inserted into the receptacle 11, an upper end 27 pushesthe flexible walls 16 and first locking members 12 apart (arrows 37).This is possible, because the flexible wall(s) 16 of the receptacle 11has a certain elasticity, and can therefore be deflected elasticallylike a leaf spring into the cavity 15. The material used for thereceptacle 11 determines, together with the thickness and the length ofthe flexible wall(s) 16, the resistance to the fastening projection 21being inserted into the receptacle 11. Generally, the flexible wall(s)16 is substantially perpendicularly disposed in the receptacle 11 and isgenerally parallel to a longitudinal axis 31 of the fastening projection21 (FIG. 11). Alternatively, the flexible wall(s) 16 could be biased,for example inwardly, to increase or decrease the resistance and travelof the flexible wall(s) 16. Generally, once the second locking member(s)23 and the first locking member(s) 12 engage, thereby locking the stud20 in place, the flexible wall(s) 16 at least partially returns to itsinitial, non-deflected position. In one embodiment, the fasteningprojection 21 and the receptacle 11 have corresponding asymmetric shapesthat unambiguously define an orientation of the mounted stud 20. Thishelps to ensure a correct arrangement of the stud 20, even if theattachment is performed in a great hurry, for example during a game.

Depending on the materials used for the receptacle 11, it can beadvantageous to provide the first locking member 12 or the upper end 27of the fastening projection 21 with laterally inclined edges or chamfers41 to facilitate insertion. The first locking member(s) 12 is typicallydisposed on a portion of the flexible wall(s) 16 closest the top surface4 of the receptacle 11, so that the majority of the lower part of thereceptacle 11 is capable of providing a reliable seat for the fasteningprojection 21.

When the fastening projection 21 of the stud 20 has been inserted intothe receptacle 11 until it stops, the first locking member(s) 12 engagesthe second locking member(s) 23 via the elastic spring-back of theflexible wall(s) 16 of the receptacle 11. This action fastens the stud20 to the sole 1. In contrast to the prior art, no additional metaland/or small components are necessary for locking. The receptacle 11itself includes the cavity(ies) 15 and the flexible wall(s) 16, whichreliably anchor the fastening projection 21.

As a result, an advantage of the present invention is realized, becauseonly two injection molding processes are necessary for manufacturing adetachable cleat system in accordance with the invention. The firstinjection molding process is required to manufacture the receptacle 11,and the second is required to manufacture the sole 1 around thepre-manufactured receptacle 11. In a particular embodiment, materialsare used which create a strong bond between the receptacle 11 and thesurrounding sole 1 in which the receptacle 11 is mounted. For example,the receptacle 11 and the sole 1 may include materials that melt, orthat may polymerize in a chemical reaction. In a preferred embodiment,the receptacle 11 is made from a material which has a greater rigidityand stiffness than the material used in the sole so that the receptaclecan better resist the mechanical loads applied by the stud. For example,the receptacle 11 is manufactured from a fiber reinforced polyamide or ametal, and the sole 1 is manufactured from a common polyamide. Thisconstruction allows for a sufficiently elastic sole 1 that enables aneasy rolling-off, depending on the respective field of use. Also, atorsional movement of the forefoot part with respect to the rearfootpart is possible with this construction.

As shown in FIGS. 1 and 3, the base member 10 itself projects like astud downwardly from the sole 1. As such, the base member 10 can have agrip-improving function and provide the necessary space in the sole 1for the arrangement of the receptacle 11. Further, the enlarged basemember 10 prevents excessive strain where the base member 10 projectsfrom the sole 1, thereby reducing the possibility of breaking-off singlestuds under peak loads. Alternatively, the receptacle 11 can beintegrated into the sole 1 without an enlarged base member 10, such thatthe lower opening of the receptacle 11 is flush with the bottom surface3 of the sole 1.

FIGS. 4-7 depict an alternative embodiment of a detachable cleat systemin accordance with the invention. The sole 100 and stud 120 are similarin nature to the sole 1 and stud 20 described hereinabove. The sole 100includes a base member 110 and a receptacle 111 disposed therein. Thereceptacle 111 includes two flexible walls 116, two cavities 115 and twofirst locking members 112 in the form of protrusions disposed on theflexible walls 116. Also included in this embodiment is an optionalinsert 130 that can stabilize and strengthen the lower part of thereceptacle 111. The stud 120 includes a ground-engaging portion 125 anda fastening portion 121 extending therefrom. The fastening portion 121includes two second locking members 123 in the form of recesses disposedon an external surface of the fastening portion 121.

As shown in FIGS. 4-7, the additional insert 130 is collar-like and isarranged around the fastening projection 121 of the stud 120 andstabilizes the fastening projection's seat at the receptacle 111. Theinsert 130 has a generally oblong shape and is disposed in a recess 141located at a distal end 142 of the base member 110. Typically, the sizeand shape of the insert 130 will correspond to the size and shape of thebase member 110. The insert 130 also includes contact areas 133 at itsfront and rear ends that improve the strength of the bond between theinsert 130 and the receptacle 111. The insert 130 in another embodimentmay be attached to the bottom surface 103 of the sole 100. Included onthe longitudinal sides of the insert 130 are cutouts 135 that allow foran unhindered interaction of the locking means 112, 123 of the fasteningprojection of the stud 120, and the elastic wall 116 of the receptacle111. Therefore, the insert 130 does not directly participate in thelocking of the stud 120; however, the insert 130 reinforces thelowermost part of the receptacle 111. A circumferential projection 132of the insert 130 fitting into a corresponding recess 128 of the stud120 further increases the stability of the seat at the receptacle 111.

In conditions where the stud 120 is subjected to particularly highmechanical loads, such as a stud at the heel of a soccer shoe, theinsert 130 can be further reinforced by an optional ring 140 (FIGS. 4-6)to increase stability and structural integrity of the cleat system. Thering 140 can be made of any material, but is preferably made from ametal, such as steel or aluminum. In a particular embodiment, the ring140 is at least partially surrounded by the insert 130, which helpsprevent the ring 140 from rusting. In the illustrated embodiment, thering 140 has a generally circular structure and includes an opening 148;however, the ring 140 can be any suitable shape that helps to reduce thedeformation of the insert 130 and the receptacle 111. Further, althoughthe illustrated ring 140 is planar, a three dimensional shape is alsoconceivable.

As discussed above with respect to the insert 130, the size and shape ofthe ring 140 generally corresponds to the size and shape of the insert130 and, by extension, the size and shape of the base member 110. Theopening 148 also corresponds to the size and shape of the receptacle 111to allow for the passage of the fastening portion 121 therethrough. Thering 140 is shown as a relatively thin piece; however, the thickness ofthe ring 140 can vary to suit a particular application.

The insert 130 can be molded from polyamide mixed with glass fibers;however, the insert 130 could be manufactured from any of the materialsand by any process described herein or known to those skilled in theart. The insert 130 may be connected to the receptacle 111 by gluing, byco-injecting the receptacle 111 and the insert 130, or by any otherknown method. In a preferred embodiment, the insert 130 consists of amaterial that is reinforced to a greater extent than the stud 120. Forexample, the insert is made from a polyamide that has a greater fibercontent than the stud 120. In one embodiment, the insert 130 ismanufactured separately and then placed in the molds in which the sole100 and receptacle 111 are produced. This method of manufacture achievesa good bond between the sole 100, the receptacle 111, and the insert130, especially when the sole 100 and the receptacle 111 are also madefrom polyamide. The insert 130 can be injection molded around the ring140 in the embodiment that includes the optional insert 130 and ring140.

FIG. 8 depicts a top surface 204 of a portion of a sole 200 having analternative cavity 215 arrangement. In this arrangement, the flexiblewalls 216 and the cavities 215 are generally arcuate and surroundsemicircularly ends of each oblong receptacle 211. When a fasteningprojection of a stud is inserted into the receptacle 211, the flexiblewalls of the receptacle 211 are deflected longitudinally, i.e., parallelwith a longitudinal axis 231 of the receptacle 211.

FIGS. 9-10 show another embodiment of a detachable cleat system inaccordance with the invention, wherein the cavities 315 of thereceptacle 311 are closed from above by means of a separate seal 360.The seal 360 includes pins 361 that are used to fasten the seal to acorrespondingly shaped recess of the receptacle 311. The seal 360 alsoincludes side areas 362 that extend into the cavities 315 of thereceptacle 311 without impairing the ability of walls 316 of thereceptacle 311 to deflect (FIG. 10). In one embodiment, the pins 361and/or the side areas 362 of the seal 360 may comprise locking elementsthat engage corresponding recesses in the receptacle 311 to avoidunintentional detachment of the seal 360.

The seal 360 helps prevent the penetration of material into the cavities315, for example, the material used to manufacture the sole 300 aroundthe pre-manufactured receptacle 311, or connecting glue. Preventingmaterial from penetrating the cavities 315 avoids the possibility of thewalls 316 of the receptacle 311 being hindered from deflecting into thecavities 315. Similarly, the seal 360 prevents penetration of materialinto the cavities 315 when an additional insole is glued to the finishedsole 300. In an alternative embodiment, the cavities 315 may be sealedin a later step by the addition of a foil, which extends over a part orthe complete area of the sole 300.

With continued reference to FIGS. 9 and 10, the ring 340 is mountedinside the receptacle 311 without using an insert 330. In thisembodiment, the receptacle 311 is injection molded around the ring 340.Compared to a separate insert 330, the manufacture of the sole 300 isfurther simplified without reducing the stability of the anchoring stud320.

The various components of the detachable cleat system can bemanufactured by, for example, injection molding or extrusion. Extrusionprocesses may be used to provide a uniform shape, such as a singlemonolithic frame for the sole 1. Insert molding can then be used toprovide the desired geometry of, for example, the receptacles 11, or thereceptacles 11 could be created in the desired locations by a subsequentmachining operation. Other manufacturing techniques include melting orbonding additional portions. For example, the base members 10 may beadhered to the sole 1 with a liquid epoxy or a hot melt adhesive, suchas ethylene vinyl acetate (EVA). In addition to adhesive bonding,portions can be solvent bonded, which entails using a solvent tofacilitate fusing of the portions to be added to the sole.

The various components of the detachable cleat system can bemanufactured from any suitable polymeric material or combination ofpolymeric materials, either with or without reinforcement. Suitablematerials include: polyurethanes, such as a thermoplastic polyurethane(TPU); ethylene vinyl acetate (EVA); thermoplastic polyether blockamides, such as the Pebax® brand sold by Elf Atochem; thermoplasticpolyester elastomers, such as the Hytrel® brand sold by DuPont; nylons,such as nylon 12, which may include 10 to 30 percent or more glass fiberreinforcement; silicones; polyethylenes; polyamides; and equivalentmaterials. Reinforcement, if used, may be by inclusion of glass orcarbon graphite fibers or para-aramid fibers, such as the Kevlar® brandsold by DuPont, or other similar method. Also, the polymeric materialsmay be used in combination with other materials, for example rubber.Additionally, ceramic, aluminum, or other metals, which combine a lowweight with high wear resistance, can be used for the studs 20. In thecase of metal studs, the fastening projection 21 may be coated with aplastic layer that can slightly deform during insertion into thereceptacle 21. Other suitable materials will be apparent to thoseskilled in the art.

Having described certain embodiments of the invention, it will beapparent to those of ordinary skill in the art that other embodimentsincorporating the concepts disclosed herein may be used withoutdeparting from the spirit and scope of the invention. For example, thewall(s) and cavity(ies) can be provided in the studs, with the matingstructure provided in the sole. Alternatively or additionally, lockingmembers may be selectively provided on fewer than all walls in allreceptacles, or along solely one side of the stud fastening projection.Each locking member may include multiple protuberances or recesses, aswell as combinations thereof. Additionally, the locking memberprotuberances and recesses need not be of square or rectangularcross-section, as depicted. They could be provided with sawtooth orangled walls to facilitate insertion and provide enhanced retentionagainst inadvertent release. Accordingly, the described embodiments areto be considered in all respects as only illustrative and notrestrictive.

1. A method of manufacturing a sole comprising: forming a sole bodyhaving a stud base comprising a ground-engaging surface; providing atleast one receptacle disposed at least partially within the stud base,the receptacle comprising a circumferential projection extending beyondthe ground-engaging surface, the circumferential projection at leastpartially defining a cavity in the receptacle; and providing at leastone stud comprising a ground-engaging portion, a fastening projectionportion extending therefrom, and forming a circumferential recess atleast partially circumscribing the fastening projection portion andadapted to engage the circumferential projection of the stud base whenthe fastening projection portion is adapted to be inserted into thecavity of the receptacle for securing the stud to the stud base, whereinthe fastening projection portion of the stud comprises a generallyoblong shape.
 2. The method of claim 1, wherein the receptacle and studbase are formed from a single piece of material.
 3. A method ofmanufacturing a sole comprising: forming a sole body having a stud basecomprising a around-engaging surface; providing at least one receptacledisposed at least partially within the stud base, the receptaclecomprising a circumferential projection extending beyond theground-engaging surface, the circumferential projection at leastpartially defining a cavity in the receptacle; and providing at leastone stud comprising a ground-engaging portion, a fastening projectionportion extending therefrom, and forming a circumferential recess atleast partially circumscribing the fastening projection portion andadapted to engage the circumferential projection of the stud base whenthe fastening projection portion is adapted to be inserted into thecavity of the receptacle for securing the stud to the stud base, whereinthe circumferential recess of the stud and the circumferentialprojection of the receptacle have complementary asymmetrical shapesunambiguously defining a specific orientation of the stud for insertion.4. The method of claim 3, wherein the receptacle and stud base areformed from a single piece of material.
 5. A method of manufacturing asole comprising: forming a sole body having a stud base comprising aground-engaging surface; providing at least one receptacle disposed atleast partially within the stud base, the receptacle comprising acircumferential projection extending beyond the ground-engaging surface,the circumferential projection at least partially defining a cavity inthe receptacle; and providing at least one stud comprising aground-engaging portion, a fastening projection portion extendingtherefrom, and forming a circumferential recess at least partiallycircumscribing the fastening projection portion and adapted to engagethe circumferential projection of the stud base when the fasteningprojection portion is adapted to be inserted into the cavity of thereceptacle for securing the stud to the stud base, wherein the cavity inthe receptacle and the fastening projection portion of the stud havecomplementary asymmetrical shapes unambiguously defining a specificorientation of the stud for insertion.
 6. The method of claim 5, whereinthe cavity in the receptacle comprises a substantially vertical sidewalland a protuberance on a portion thereof, and wherein at least onesidewall of the fastening projection portion of the stud defines amating recess for engaging the protuberance when the fasteningprojection portion is inserted into the receptacle.
 7. The method ofclaim 5, wherein the fastening projection portion of the stud comprisesa generally T-shaped cross-section for insertion of the stud into thereceptacle in a single orientation.
 8. The method of claim 5, whereinthe receptacle and stud base are formed from a single piece of material.9. A method of manufacturing a sole for an article of footwear having atleast one stud adapted to engage releasably the sole: forming a solebody having at least one receptacle forming a cavity for receiving astud; and providing at least one stud comprising: a body comprising aground-engaging portion and a fastening projection portion extendingfrom the ground-engaging portion; and a circumferential recess formed inthe body of the stud at least partially circumscribing the fasteningprojection portion, wherein the fastening projection portion and thecircumferential recess are adapted to mate with a correspondingreceptacle disposed in the sole body to stabilize the stud body whenengaged with the sole, wherein the fastening projection portioncomprises a generally oblong shape to secure the stud against rotationwhen engaged with the sole.
 10. A method of manufacturing a sole for anarticle of footwear having at least one stud adapted to engagereleasably the sole: forming a sole body having at least one receptacleforming a cavity for receiving a stud; and providing at least one studcomprising: a body comprising a ground-engaging portion and a fasteningprojection portion extending from the ground-engaging portion; and acircumferential recess formed in the body of the stud at least partiallycircumscribing the fastening projection portion, wherein the fasteningprojection portion and the circumferential recess are adapted to matewith a corresponding receptacle disposed in the sole body to stabilizethe stud body when engaged with the sole, wherein the circumferentialrecess of the stud is adapted to have a complementary asymmetrical shapeto a projection of the receptacle unambiguously defining a specificorientation of the stud for mating with the receptacle and securing thestud against rotation when engaged with the sole.
 11. A method ofmanufacturing a sole for an article of footwear having at least one studadapted to engage releasably the sole: forming a sole body having atleast one receptacle forming a cavity for receiving a stud; andproviding at least one stud comprising: a body comprising aground-engaging portion and a fastening projection portion extendingfrom the ground-engaging portion; and a circumferential recess formed inthe body of the stud at least partially circumscribing the fasteningprojection portion, wherein the fastening projection portion and thecircumferential recess are adapted to mate with a correspondingreceptacle disposed in the sole body to stabilize the stud body whenengaged with the sole, wherein the fastening projection portion of thestud is adapted to have a complementary asymmetrical shape to a cavityformed in the receptacle unambiguously defining a specific orientationof the stud for mating with the receptacle and securing the stud againstrotation when engaged with the sole.
 12. The method of claim 11, whereinat least one sidewall of the fastening projection portion of the studdefines a mating recess adapted to engage a protuberance on a portion ofa sidewall in the cavity of the receptacle when the fastening projectionis inserted into the receptacle.
 13. The method of claim 11, wherein thefastening projection portion of the stud comprises a generally T-shapedcross-section for insertion of the stud into the receptacle in a singleorientation.
 14. A method of manufacturing an article of footwear havinga sole, the method comprising: forming an upper; attaching at least onesole layer to the upper, the sole layer comprising a stud base having aground-engaging surface and at least one receptacle disposed at leastpartially within the stud base, the receptacle comprising acircumferential projection extending beyond the ground-engaging surface,the circumferential projection at least partially defining a cavity inthe receptacle; and providing at least one stud comprising aground-engaging portion, a fastening projection portion extendingtherefrom, and forming a circumferential recess at least partiallycircumscribing the fastening projection portion and adapted to engagethe circumferential projection of the stud base when the fasteningprojection portion is adapted to be inserted into the cavity of thereceptacle for securing the stud to the stud base, wherein the fasteningprojection portion of the stud comprises a generally oblong shape.
 15. Amethod of manufacturing an article of footwear having a sole, the methodcomprising: forming an upper; attaching at least one sole layer to theupper, the sole layer comprising a stud base having a ground-engagingsurface and at least one receptacle disposed at least partially withinthe stud base, the receptacle comprising a circumferential projectionextending beyond the ground-engaging surface, the circumferentialprojection at least partially defining a cavity in the receptacle; andproviding at least one stud comprising a ground-engaging portion, afastening projection portion extending therefrom, and forming acircumferential recess at least partially circumscribing the fasteningprojection portion and adapted to engage the circumferential projectionof the stud base when the fastening projection portion is adapted to beinserted into the cavity of the receptacle for securing the stud to thestud base, wherein the circumferential recess of the stud and thecircumferential projection of the receptacle have complementaryasymmetrical shapes unambiguously defining a specific orientation of thestud for insertion into the sole.
 16. A method of manufacturing anarticle of footwear having a sole, the method comprising: forming anupper; attaching at least one sole layer to the upper, the sole layercomprising a stud base having a ground-engaging surface and at least onereceptacle disposed at least partially within the stud base, thereceptacle comprising a circumferential projection extending beyond theground-engaging surface, the circumferential projection at leastpartially defining a cavity in the receptacle; and providing at leastone stud comprising a ground-engaging portion, a fastening projectionportion extending therefrom, and forming a circumferential recess atleast partially circumscribing the fastening projection portion andadapted to engage the circumferential projection of the stud base whenthe fastening projection portion is adapted to be inserted into thecavity of the receptacle for securing the stud to the stud base, whereinthe cavity in the receptacle and the fastening projection portion of thestud have complementary asymmetrical shapes unambiguously defining aspecific orientation of the stud for insertion into the sole.
 17. Themethod of claim 16, wherein the cavity in the receptacle comprises asubstantially vertical sidewall and a protuberance on a portion thereof,and wherein at least one sidewall of the fastening projection portion ofthe stud defines a mating recess for engaging the protuberance when thefastening projection portion is inserted into the receptacle.
 18. Themethod of claim 16, wherein the fastening projection portion of the studcomprises a generally T-shaped cross-section for insertion of the studinto the receptacle in a single orientation.